The new playbook for industrial performance

Recently, one of our steel clients came to us with a problem. They were producing nearly 15% below their daily target, with recurring blast furnace operational issues such as excessive thermal load, stave failures, and operational instability. These challenges demanded more than quick technical fixes. They required a fundamental shift in how the operation was understood, managed, and improved.

Similar issues are shared by many steel producers. And with global oversupply putting increasing pressure on margins, steel producers must find ways to deliver high-quality output at the lowest possible cost.

A structured approach built for results

To address this, we partnered with our client to apply a strategic transformation framework built on three integrated phases:

• Diagnostic: A six-week deep dive into operations, data, and stakeholder insights.
• Planning: Development of a structured roadmap with 23 cross-functional initiatives.
• Execution: Launched quick wins and established a Technical Project Management Office (PMO), supported by subject-matter experts (SMEs) to drive sustained change.

What makes Hatch’s execution model different is our one-team approach to delivering sustained financial improvement. We work alongside client teams to co-own the process and accelerate decision making. This close partnership ensures that improvements are implemented quickly and in ways that are technically sound, executable, and scalable.

Our execution philosophy is anchored in four core principles that consistently drive impact:

From data to decisions: a holistic diagnostic that goes beyond engineering

Our diagnostic combined production data, stakeholder interviews, and benchmarking against best-in-class practices. The analysis revealed that most production losses came from three interrelated factors: thermal load, casting practices, and process instability.

The team mapped out 23 initiatives to close performance gaps and unlock full potential across the cast house, furnace operation, stave strategy, upstream, and downstream areas. These initiatives were sequenced into a phased roadmap to support both short-term stabilization and long-term growth.

What makes this transformation unique is how engineering solutions were paired with operational and behavioral shifts. For example:

• Zero-gap casting: Instead of treating casting delays as inevitable, we identified that zero-gap time casting was technically feasible; the challenges were procedural and cultural. By engaging crews and redesigning routines, the blast furnace began reducing gap times, leading to improved slag drainage and reduced stave thermal load.
• Wind index control: Rather than relying on intuition, Hatch introduced a wind index software tool to help operators proactively adjust wind rates based on differential pressure. This decision-support tool turned reactive adjustments into data-driven actions, reducing the risk of overblowing and stave heat stress.
• Stave strategy: Stave failures were not only a maintenance issue but also a symptom of deeper operations and monitoring gaps. We proposed a long-term strategy that includes improved leak detection, enhanced stave thermocouple accuracy, stave replacement planning, and cooling system upgrades to ensure reliability and extend campaign life.
• Upstream and downstream logistics: From coke oven scheduling to ladle carrier mobile equipment availability, the team addressed supply chain bottlenecks that were silently eroding productivity. Initiatives included coke sampling reform, sinter feed optimization, and automated ladle tracking, transforming logistics into a lever for performance.

To build momentum, the team selected three quick wins based on their high impact and low complexity and cost. More importantly, they served as change management vehicles, engaging crews, shifting mindsets, and demonstrating that transformation was possible and already underway.

Building governance that sustains change

Execution is where many transformations falter. To ensure discipline and accountability, Hatch helped its client build a Technical PMO that functioned as both a project office and a core business capability.

The PMO governs initiative planning, tracks key performance indicators, facilitates weekly decision making, and ensures cross-functional alignment. It is the backbone of transformation, enabling parallel execution and continuous improvement.

While specific metrics remain confidential, the trajectory is clear: the blast furnace is stabilizing, production gaps are closing, and the organization is shifting from reactive firefighting to proactive performance management.

Setting a new standard for industrial performance

This transformation reflects a shift from isolated technical fixes to a comprehensive strategy that combines engineering expertise with operational discipline and cultural alignment. By connecting diagnostics, planning, and execution within a single framework, we helped our client recover lost production and build the internal capabilities needed for long-term success.

The impact extends beyond the blast furnace. It introduced a new way of thinking about industrial performance, one where decisions are driven by data, teams are engaged, and governance supports continuous progress.

For steel producers facing pressure to improve reliability, productivity, and sustainability, this approach offers a practical and proven path forward.

Our one-team execution model, grounded in embedded expertise, joint accountability, and a relentless focus on financial outcomes, ensures that transformation is both achievable and lasting.

How steel producers can apply this playbook

Steel leaders who master this disciplined, integrated approach will set the pace for the next era of industrial performance. Hatch can help you achieve similar results. Whether you are dealing with persistent performance gaps or preparing for a broader transformation, our teams work with you as partners to design and deliver solutions that are technically sound, operationally viable, and strategically aligned.